1. 1 Battery Safety, Servicing & Testing R. Bortignon

2. 2 Slideshow Contents battery function & related information battery function & related information safe battery handling procedures safe battery handling procedures battery service battery service battery testing battery testing alternator testing alternator testing how to safely charge a battery how to safely charge a battery jump starting a vehicle jump starting a vehicle

3. 3 Purpose of the Battery… provides the electrical power needed to start the engine provides the electrical power needed to start the engine powers the starter motor and ignition & fuel system powers the starter motor and ignition & fuel system

4. Starter Function 4

5. 5 Purpose of the Battery… once the engine is started, the alternator provides all the electrical energy for the ignition system, computers, lights, radio, horn and other accessories once the engine is started, the alternator provides all the electrical energy for the ignition system, computers, lights, radio, horn and other accessories alternator converts mechanical energy (belt-driven pulley) to electrical energy alternator converts mechanical energy (belt-driven pulley) to electrical energy

6. 6 Important info about automotive batteries… they converts chemical energy into electrical energy they converts chemical energy into electrical energy they produce 12.6 volts they produce 12.6 volts 6 individual cells produce 2.1 volts each6 individual cells produce 2.1 volts each they cost approximately $50 to $120 they cost approximately $50 to $120 battery warranties range from 3 to 6 years battery warranties range from 3 to 6 years average battery life expectancy is 3 to 6 years average battery life expectancy is 3 to 6 years battery power is rated in cold cranking amps or CCA’s battery power is rated in cold cranking amps or CCA’s

7. 7 Battery Safety Batteries contain a liquid called electrolyte which contains sulphuric acid Batteries contain a liquid called electrolyte which contains sulphuric acid You must be careful not to splash the electrolyte in your eyes or get it on your skin! You must be careful not to splash the electrolyte in your eyes or get it on your skin! Batteries give off hydrogen gas thru vents in the top of the battery Batteries give off hydrogen gas thru vents in the top of the battery Keep sparks & flames away from the battery!!! Keep sparks & flames away from the battery!!!

8. 8

9. 9 Servicing & Safe Battery Handling First step in a battery service… 1. Disconnect & clean battery terminals and posts a) always remove negative first, then positive  Negative is usually black or marked with – and it connects to ground  Positive is usually red or marked with + and it connects to the starter motor or starter relay terminal puller Wear eye protection!!!

10. 10 replace any bolt/nut, terminal or cable if damaged replace any bolt/nut, terminal or cable if damaged

11. 11 Use gloves when servicing batteries…

12. 12

13. 13

14. 14 b) always reinstall positive first, then negative remember: NPPNremember: NPPN ensure the terminals cannot be moved by handensure the terminals cannot be moved by hand coat the terminals with spray paint or terminal protector to reduce further corrosioncoat the terminals with spray paint or terminal protector to reduce further corrosion

15. 15 Step 2 in Battery Service… 2. Check the electrolyte level in each cell some vent caps are not removable – ask Roger if you are unsure! some vent caps are not removable – ask Roger if you are unsure! the electrolyte should cover the plates the electrolyte should cover the plates add water if needed, but do not overfill! add water if needed, but do not overfill!

16. 16 fill cells slowly - normally, very little water is required!

17. 17 Step 3 in Battery Service 3) use a rag & clean the top of the battery so current won’t leak between the terminals

18. 18 Battery Charging next 2 slides… next 2 slides…

19. 19 Battery Charging 1. Service the battery. 2. Connect the battery charger cables. (red to positive, black to negative) 3. Set the charge rate to LOW. 4. Set the timer to 60 minutes. 5. Plug the charger in. monitor battery temperature by placing your hand on the case – if it gets too hot, turn off the charger – the battery may be defective!

20. 20 Unhooking the Battery Charger 1. Unplug the charger!!! 2. Disconnect the cables. 3. Check the battery’s voltage. (should be 12 volts)

21. 21 Battery Testing next 4 slides… next 4 slides…

22. 22 Battery Testing To test a battery you will use the VAT-40 to perform a load test To test a battery you will use the VAT-40 to perform a load test load test tells us if the battery can deliver the power needed to start the engine load test tells us if the battery can deliver the power needed to start the engine before you perform a load test… before you perform a load test… service the battery service the battery ensure the battery is fully charged (12 volts) ensure the battery is fully charged (12 volts) to do this, connect a voltmeter {+ to +, - to -} to do this, connect a voltmeter {+ to +, - to -} if the voltage is <12 volts, it will have to be charged if the voltage is <12 volts, it will have to be charged

23. 23 Using the VAT-40 1. Connect the cables as follows… 2 large load leads red to positive, black to negative 2 large load leads red to positive, black to negative set the volt selector to INT 18V set the volt selector to INT 18V green inductive pick-up around one of the load leads green inductive pick-up around one of the load leads

24. 24 VAT-40 Step #2 2. Determine the CCA of the battery look for a sticker on the battery that indicates the CCA look for a sticker on the battery that indicates the CCA or look in “Mitchell” to determine the CCA of the original battery or look in “Mitchell” to determine the CCA of the original battery if all else fails, assume it is a 500 CCA battery if all else fails, assume it is a 500 CCA battery

25. 25 VAT-40 Step #3 3. Pull out ½ the CCA or 3 times the amp/hour rating out of the battery for 10 seconds (e.g. on a 650 CCA battery, pull 325 amps out during the load test) the voltage should stay above 9.6 volts the voltage should stay above 9.6 volts if the voltage drops below 9.6 volts, the battery will have to be replaced if the voltage drops below 9.6 volts, the battery will have to be replaced

26. 26 Alternator Testing 1. Check the belt tension (≈1/2” or 13mm slack) 2. Are the wires on the back of the alternator corroded, loose or burned?

27. 27 Alternator Testing 3. Hook up the VAT-40 Do not turn the load control knob! 4. Start the engine. Alternator should produce between 13.5 & 14.5 volts

28. 28 Jump Starting a Battery Connect the jumper cables in this order… 1.connect positive to positive 2.connect negative to ground Ground is any solid, unpainted metal part such as the frame or a bracket that is bolted to the engine Ground is any solid, unpainted metal part such as the frame or a bracket that is bolted to the engine 3.start the engine 4.use a battery charger to recharge the dead battery Do not allow the clamps to touch each otherDo not allow the clamps to touch each other Do not jump the battery if you suspect there is a fuel leakDo not jump the battery if you suspect there is a fuel leak